Disassembling and assembling gearbox

Synchronizing Gear Box Assemble Photos

911 Carrera 4 Manual Transmission, Controls, Case

Note when:

No.

Description

Qty.

Removing

Installing

1

Hexagon nut

10

Tighten with 23 Nm

(17ft.lb.)

2

Washer

9

3

Holder

1

4

Intermediate case

1

5

Seal

1

Replace

6

Collar nut

1

Select 5th gear, block

Tighten with 140 Nm

input shaft with Special

(103 ft.lt>.) (and notch

Tool 9253

the collar to secure)

7

Hexagon head screw

1

Tighten with 23 Nm

(17 ft.lb.)

8

Washer

1

9

Cylindrical-roller bearing

1

Pull out with Special Tool

Heat up to approx.

9284

120 °C (248 °F)

10

Friction washer

1

Mount in correct posi

tion. The large flat-

ground side points

towards needle bearing

(No. 13)

11

Loose gear, reverse gear

1

Only replace in sets

12

Synchronizing disk

1

Mark for refitting

Check for wear, assem

ble with the same gear

wheel. (Cogs towards

driver dogs)

13

Needle cage

1

Mark for refitting

Assemble with the same

gear wheel

14

Sleeve

1

Mark for refitting

Assemble with the same

gear wheel

15

Guide sleeve with gear

1

Remove together with shift

Gear shift sleeve and

shift sleeve and synchroni

fork

guide sleeve are

zing components

matched

16

Shift fork

1

Remove together with

Adjust with Special Tool

gear shift sleeve and

9286 and/or 9286/1

guide sleeve

Note when:

No.

Description

Qty.

Removing

Installing

17

Synchronizing disk

1

Mark for refitting

Check for wear, assem

ble with the same gear

wheel (cogs towards

driver dogs)

18

Loose gear - 5th gear

1

Only replace in pairs

19

Needle cage

1

Mark for refitting

Assemble with the same

gear wheel

20

Inner bearing race

1

Pull out with suitable claw

Heat up to approx.

puller

120 °C (248 °F)

21

Fixed gear - reverse gear

1

Only replace in sets

22

Spacer

1

23

Fixed gear - 5th gear

1

Only replace in pairs

24

Oil guide tube

1

25

O-ring

Replace

26

Transmission

1

911 Carrera 4 Manual Transmission, Controls, Case

Notes on disassembling and assembling

Disassembling

1. Pull cylindrical-roller bearing and needle-bearing sleeve from the hollow shaft with Special Tool 9284.

Porsche Tool 9284
175-34

Note

Always use Special Tool 9284. If the drive pinion is used as a support, this may cause damage to the gear wheels in the transmission.

Assembly

1. Adjust shift fork for 5th and reverse gear:

Secure hollow shaft with Special Tool 9286 and/or 9286/1.

Insert shim "s" and counter Special Tool 9285 hand tight.

Tighten lock nut.

183-34

Adjust gear shift sleeve with the gear fork in such a way that it is exactly centrally located in idle position.

186-34

Tighten hexagon head screws for shift fork with 23 Nm (17 ft.lb.)-

911 Carrera 4 Manual Transmission, Controls, Case

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